Two-piece transaction card construction

ABSTRACT

The disclosed embodiments generally relate to transaction card constructions, and particularly, to a two-piece transaction card construction. Disclosed embodiments include a generally planar first card component including a first surface and a generally planar second card component including a second surface wherein the first card component is separate from the second card component. In disclosed embodiments, for example, the generally planar first card component and the generally planar second card component may be configured such that one forms a cavity and the other forms an inlay component configured to be seated within the cavity. In other embodiments the generally planar first card component and the generally planar second card component may be configured such that one forms a container and the other forms a lid configured to close the container.

PRIORITY CLAIM

This application is a continuation of U.S. patent application Ser. No.16/277,222, filed Feb. 15, 2019 (currently pending), which is acontinuation of U.S. patent application Ser. No. 16/115,098, filed Aug.28, 2018, now U.S. Pat. No. 10,248,901, which is a continuation of U.S.patent application Ser. No. 15/875,213, filed Jan. 19, 2018, now U.S.Pat. No. 10,089,571, which is a continuation of U.S. patent applicationSer. No. 15/236,305, filed Aug. 12, 2016, now U.S. Pat. No. 9,965,716,which claims priority under 35 U.S.C. § 119 to U.S. ProvisionalApplication No. 62/205,396, filed on Aug. 14, 2015, and entitled“Two-Piece Transaction Card Construction,” and claims priority under 35U.S.C. § 119 to U.S. Provisional Application No. 62/242,039, filed onOct. 15, 2015, and entitled “Two-Piece Transaction Card Construction.”The disclosures of the above-identified applications are expresslyincorporated herein by reference in their entireties.

TECHNICAL FIELD

The disclosed embodiments generally relate to transaction cardconstructions, and particularly, to a two-piece transaction cardconstruction.

BACKGROUND

Transaction cards, such as credit and debit cards, have increasinglybecome a primary means for customers to complete financial transactions.Typically, transaction cards are cast out of a plastic material as asingle piece. For example, a typical credit card may be manufactured outof plastic such as polycarbonate (PC) or polyvinyl chloride (PVC) usingan injection molding process. The plastic card may then be modified toadd functional and/or visual features. For example, a magnetic strip maybe affixed to one side, the card may be stamped with the card number andcustomer name, and color or a design may be added for appearance.

But many transaction card providers are moving away from using magneticstrip technology and now additionally or alternatively include moreadvanced transaction components attached to or embedded within atransaction card. For example, some transaction cards now includemicrochips (e.g., microchips based on the Europay, MasterCard, and Visastandard, also called “EMV chips”) that more securely and efficientlymanage card and customer information. Some cards now include near fieldcommunication (NFC) and/or radio-frequency identification (RFID)components that can wirelessly communicate with outside devices (e.g., apoint of sale device, mobile device, etc.). While these types oftechnology provide several advantages to customers, the conventional,one-piece transaction card construction may not be ideal for providingthem in a transaction card.

For example, in order to accommodate more recent technology in atraditional single-piece card, the card must be milled to create spacefor an transaction component (e.g., an EMV chip) and/or the plasticmaterial may be cast around an transaction component (e.g., an NFCantenna) during the manufacturing process. These processes, however,limit the transaction cards to being used with that particulartransaction component. In other words, a conventional, one-piecetransaction card is not configured to adapt to multiple types oftransaction components. For example, if a transaction card is milled toinclude a space for an EMV chip, the card is limited to microchips thatfit in that space. Similarly, if card material is cast around an NFCantenna, the NFC antenna cannot be removed without destroying thetransaction card.

Conventional transaction cards suffer from additional drawbacks. Forexample, typical materials used to manufacture the cards (e.g., PC andPVC plastic) result in transaction cards that are not very durable, areprone to scratches, wear, and becoming dirty or stained, and lack anyergonomic features and/or textural feel. In general, one-piececonstructions limit the sophistication and potential utility of atransaction card by effectively removing the potential for customizationand interchangeability.

The present disclosure is directed to overcoming one or more of theproblems set forth above and/or other problems associated withconventional transaction card constructions.

SUMMARY

The disclosed embodiments relate to a credit card that includes atwo-piece construction.

In one aspect, the present disclosure is directed to a transaction card.The transaction card may include a generally planar first card componentincluding a first surface. The transaction card may also include agenerally planar second card component including a second surface anddefining a cavity. The first card component may be separate from thesecond card component and at least partially insertable into the cavity.The first surface may form a first exterior surface and the secondsurface may form a second exterior surface when the first card componentis in the cavity. The transaction card may be defined by a thickness ofless than approximately 2 mm.

In another aspect, the present disclosure is directed to a method ofmanufacturing a transaction card. The method may include forming agenerally planar first card component from a first material. The methodmay also include forming a generally planar second card component from asecond material, the second card component including a cavity. Themethod may further include inserting the first card component into thecavity and attaching the first card component to the second cardcomponent. The first material may be different than the second material.The transaction card may be defined by a thickness of less thanapproximately 2 mm.

In another aspect, the present disclosure is directed to a transactioncard, the transaction card including a card frame. The card frame mayinclude a generally planar first card component defining a space and agenerally planar second card component, separate from the first cardcomponent and attachable thereto to at least partially enclose thespace. The card frame may be configured to hold at least one transactioncomponent in the space and may be defined by a thickness that is lessthan 0.10 inches.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the disclosed embodiments, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate disclosed embodiments and,together with the description, serve to explain the disclosedembodiments. In the drawings:

FIG. 1 is a block diagram of an example of a transaction system,consistent with disclosed embodiments;

FIG. 2 is an exploded-view illustration of a transaction card,consistent with disclosed embodiments;

FIG. 3A is a top-view illustration of an embodiment of a transactioncard, consistent with disclosed embodiments;

FIG. 3B is a bottom-view illustration of the transaction card of FIG.3A;

FIGS. 4A-4B are illustrations of a transaction card with an alternativeornamental design;

FIGS. 5A-5B are illustrations of a transaction card with anotheralternative ornamental design;

FIGS. 6A-6B are illustrations of a transaction card with yet anotheralternative ornamental design;

FIG. 7 is a cross-sectional illustration taken along line 5-5 of FIG.3A, consistent with disclosed embodiments;

FIG. 8A is a top-view illustration of an embodiment of a transactioncard, consistent with disclosed embodiments;

FIG. 8B is a bottom-view illustration of the transaction card of FIG.8A;

FIG. 9 is a cross-sectional illustration taken along line 6-6 of FIG.8A, consistent with disclosed embodiments;

FIGS. 10A-10B are illustrations of an embodiment of a transaction cardthat includes tear-away portions, consistent with disclosed embodiments.

DETAILED DESCRIPTION

Reference will now be made in detail to the disclosed embodiments,examples of which are illustrated in the accompanying drawings. Whereverconvenient, the same reference numbers will be used throughout thedrawings to refer to the same or like parts.

Disclosed embodiments include a two-piece transaction card. For example,disclosed embodiments include a two-piece transaction card having twoseparate card components that may be freely movable independent of eachother and connectable to form the transaction card. In some embodiments,the two card components, when connected, may define a space forreceiving at least one transaction component. Various methods may beused to manufacture the separate card components out of different typesof materials that are suitable for satisfying certain criteria orpreferences. In addition, the construction of the separate componentsmay allow for ease of assembly, as well as customization andinterchangeability.

The term “transaction card,” as used herein, may refer to any physicalcard product that is configured to provide information, such asfinancial information (e.g., card numbers, account numbers, etc.),quasi-financial information (e.g., rewards balance, discountinformation, etc.) and/or individual-identifying information (e.g.,name, address, etc.), to another device. Examples of transaction cardsinclude credit cards, debit cards, gift cards, rewards cards, frequentflyer cards, merchant-specific cards, discount cards, identificationcards, and driver's licenses, but are not limited thereto.

FIG. 1 illustrates a transaction system 100. Transaction system 100 maybe a computing system configured to receive and send information betweenthe components of transaction system 100 and with components outside ofsystem 100. Transaction system 100 may include a financial serviceprovider system 110 and a merchant system 120 connected by a network130. It should be understood, however, that transaction system 100 mayinclude additional and/or alternative components.

Financial service provider system 110 may be one or more computersystems associated with an entity that provides financial services. Forexample, the entity may be a bank, credit union, credit card issuer, orother type of financial service entity that generates, provides,manages, and/or maintains financial service accounts for one or morecustomers. Financial service accounts may include, for example, creditcard accounts, checking accounts, savings accounts, loan accounts,reward accounts, and any other types of financial service account knownto those skilled in the art. Financial service accounts may beassociated with physical financial service transaction cards, such as acredit or debit cards that a user may carry on their person and use toperform financial service transactions, such as purchasing goods and/orservices at a point of sale (POS) terminal. Financial service accountsmay also be associated with electronic financial products and services,such as a digital wallet or similar account that may be used to performelectronic transactions, such as purchasing goods and/or servicesonline. In some embodiments, financial service provider system 110 maybe associated with an organization other than a financial institution,including a gift or reward card administrator, an airline or frequentflyer administrator, a merchant (which may in some embodiments beassociated with merchant system 120), a government institution (e.g., anagency), or the like.

Merchant system 120 may be one or more computer systems associated witha merchant. For example, merchant system 120 may be associated with anentity that provides goods and/or services (e.g., a retail store). Themerchant may include brick-and-mortar location(s) that a customer mayphysically visit and purchase goods and services. Such physicallocations may include computing devices (e.g., merchant system 120) thatperform financial service transactions with customers (e.g., POSterminal(s), kiosks, etc.). Additionally or alternatively, merchantsystem 120 may be associated with a merchant who provides electronicshopping mechanisms, such as a website or a similar online location thatconsumers may access using a computer through browser software, a mobileapplication, or similar software. Merchant system 120 may include aclient device, such as a laptop computer, desktop computer, smart phone,or tablet, that a customer may operate to accesses the electronicshopping mechanism.

Network 130 may be any type of network that facilitates communicationsand data transfer between components of transaction system 100, such as,for example, financial service provider system 110 and merchant system120. Network 130 may be a Local Area Network (LAN), a Wide Area Network(WAN), such as the Internet, and may be a single network or acombination of networks. Network 130 is not limited to the aboveexamples and transaction system 100 may implement any type of networkthat allows the entities (shown and not shown) of transaction system 100to exchange data and information.

Transaction system 100 may be configured to conduct a transactionassociated with the use of a transaction card 140. In one example,financial service provider system 110 may provide transaction card 140to a customer for use in conducting transactions associated with afinancial service account held by the customer. In an example of onesuch transaction, the customer may use transaction card 140 at amerchant location to make a purchase. During the course of the purchase,information may be transferred from transaction card 140 to merchantsystem 120 (e.g., a point of sale device). Merchant system 120 maycommunicate with financial service provider system 110 via network 130to complete the transaction. For example, merchant system 120 mayreceive account information from transaction card 140. Merchant system120 may transmit the account information and a purchase amount, amongother transaction information, to financial service provider system 110.Financial service provider system 110 may settle the transaction bytransferring funds from the customer's financial service account to afinancial service account associated with the merchant.

While transaction system 100 and transaction card 140 are depicted anddescribed in relation to transactions that involve customers, merchants,and financial service providers, it should be understood that theseentities are used only as an example to illustrate one environment inwhich transaction card 140 may be used. Moreover, it should beunderstood that transaction card 140 is not limited to financialproducts and may be any physical card product that is configured toprovide information to another device. For example, transaction card 140may be an identification card configured to provide information to adevice in order to identify the holder of the card (e.g., driver'slicense) or provide information about the holder of the card (e.g.,insurance card).

In an embodiment, transaction card 140 may include a card frame 142. Insome embodiments, card frame 142 may include at least two separatecomponents that, when secured to each other, form transaction card 140.For example, transaction card 140 may include two-piece constructionthat includes a first card component that forms a first surface oftransaction card 140 and a second card component that forms a secondsurface of transaction card 140. Additional components may also beincluded.

In some embodiments, transaction card 140 may further include antransaction component 144. Transaction component 144 may include one ormore electronic devices and/or elements configured to receive, store,process, provide, transfer, send, delete, and/or generate information.For example, transaction component 144 may be a microchip (e.g., EMVchip), a communication device (e.g., NFC antenna, Bluetooth® device,WiFi device, RFID device), etc. Transaction component 144 may be securedto card frame 142 in such a way that allows card frame 142 to carrytransaction component 144 while maintaining a utility of transactioncomponent 144 (i.e., allowing transaction component 144 to interact withmerchant system 120). In other embodiments, transaction component 144need not necessarily be electronic. For example, in some embodiments,component 144 may comprise one or more of a magnetic strip, a barcode, aQuick Response (QR) code, or the like.

FIG. 2 illustrates an embodiment of transaction card 140. In theembodiment of FIG. 2, transaction card 140 includes a two-piececonstruction. For example, card frame 142 may include two separate,independently movable card components: a generally planar lower cardcomponent 202 and a generally planar upper card component 204. Forexample, in one embodiment, card frame 142 may include cavity/inlayconstruction in which lower card component 202 forms a cavity and uppercard component 204 forms an inlay component configured to be seatedwithin the cavity. It should be understood, however, that otherconfigurations are possible. For example, transaction card 140 mayinclude a “bucket-and-lid” construction in which lower card component202 forms a container and upper card component 204 forms a lid that isconfigured to close the container and that rests on a rim of lower cardcomponent 202.

In an embodiment, lower card component 202 may include a bottom wall206, a projecting wall 208, and a lip 210. Bottom wall 206 may define afirst side of transaction card 140. For example, a bottom surface ofbottom wall 206 may form a first exterior surface 212 of transactioncard 140. In addition, a top surface of bottom wall 206 may form a firstinterior surface 214. Projecting wall 208 may extend away from bottomwall 206 and form at least a portion of a thickness of transaction card140. Bottom wall 206 and projecting wall 208 may together define acavity in a space 216. Lip 210 may be a surface that is formed by athickness of projecting wall 208 and/or is a separate surface thatextends away from projecting wall 208 (toward and/or away from space216). Lip 210 may form a support surface for at least a portion of uppercard component 204.

In an embodiment, upper card component 204 may include a top wall 218and an alignment wall 220. Top wall 218 may define a second side oftransaction card 140. For example, a top surface of top wall 218 mayform a second exterior surface 222 of transaction card 140. In addition,a bottom surface of top wall 218 may form a second interior surface 224.In some embodiments, alignment wall 220 may define a thickness of uppercard component 204. For example, alignment wall 220 may be a bevelededge of top wall 218. In other embodiments, alignment wall 220 mayextend away from top wall 218 at a distance spaced from an edge of topwall 218. In this way, alignment wall 220 and a perimeter portion of topwall 218 may define a channel 226 that extends around at least a portionof the perimeter of top wall 218. Alignment wall 220 may cover an entiremiddle portion of top wall 218 or may be formed as a border with a spacetherebetween. Further, it should be understood that some embodiments maynot include alignment wall 220.

Lower card component 202 and upper card component 204 may be securableto each other to at least partially enclose space 216. For example,upper card component 204 may be placed on top of lower card component202 such that a perimeter portion of top wall 218 rests on lip 210.Attachment may be guided by alignment wall 220, which may be sized toseat within space 216 such that an outer surface thereof contacts aninner surface of projecting wall 208.

Lower card component 202 and upper card component 204 may be permanentlyor temporarily secured to each other to form a complete card frame 142.For example, lower card component 202 may be secured to upper cardcomponent 204 using an adhesive, or by overmolding, pressure fit,interference fit, clasp, tongue-in-groove, post-and-hole, etc. If lowercard component 202 and upper card component 204 are temporarily securedto each other, an attachment feature (e.g., for hinged attachment,sliding attachment, etc.) may be included to allow card frame 142 to bedisassembled. Other techniques for securing lower card component 202 toupper card component 204 may be apparent to those of skill in the art.

The configuration of card frame 142, with lower card component 202secured to upper card component 204, may allow space 216 to holdtransaction components 144. In an embodiment, transaction components 144may include a first transaction component 228 and a second transactioncomponent 230 which are positioned within enclosed space 216. In oneexample, first transaction component 228 may be an NFC antenna andsecond transaction component 230 may be an EMV chip. It should beunderstood, however, that first transaction component 228 and secondtransaction component 230 are examples, and that other configurationsare possible (e.g., transaction card 140 may include additional and/oralternative transaction components, or may include only one of first andsecond transaction components 228, 230).

Transaction components 144 may be positioned and/or secured within space216 in any manner. In one embodiment, lower card component 202 and uppercard component 204 may be sized such that transaction components 144 aresandwiched therebetween and held in place by pressure and/or lack ofspace for movement. In other embodiments, transaction components 144 maysecured to one or more of lower card component 202 and upper cardcomponent 204 with an adhesive or embedded in an adhesive material thatis used to attach lower card component 202 to upper card component 204.

In another embodiment, card frame 142 and/or transaction components 144may include one or more alignment features configured to position and/orsecure one or more of transaction components 144 within space 216. Forexample, lower card component 202 may include a first alignment feature232 in the form of a plurality of posts. First transaction component 228may include a second alignment feature 234 in the form of a plurality ofopenings. The posts of first alignment feature 232 may be placed throughthe openings of second alignment feature 234 in order to properlyposition first transaction component 228 within space 262.

In another example, upper card component 204 may include a thirdalignment feature 236 in the form of one or more openings for receivingat least a portion of second transaction component 230. For example,third alignment feature 236 may include a window or plurality of windowsthat allows a portion or portions of second transaction component 230 toproject therethrough. This allows a contact portion of secondtransaction component 230 to be exposed outside of space 216. Forexample, in an embodiment in which second transaction component 230 isan EMV chip, third alignment feature 236 allows a contact portion of theEMV chip to be exposed. In one embodiment (not shown), alignment feature236 may include a plurality of windows for receiving a plurality ofcontact adapters for allowing an electrical connection to be establishedwith an EMV chip positioned in space 216.

FIGS. 3A-3B further illustrate an embodiment of transaction card 140.FIG. 3A illustrates a top-view of transaction card 140. FIG. 3Billustrates a bottom-view of transaction card 140. As shown in FIGS.3A-3B, transaction card 140 may include generally planar first exteriorsurface 212 and generally planar second exterior surface 222. Exteriorsurfaces 212, 222 may be similar in size to that of conventionaltransaction cards. Lower card component 202 and upper card component 204may be configured such that exterior surfaces 212, 222 have any shape,such as a shape selected for its ornamental or aesthetic design. FIGS.2, 3A, and 3B depict a first such shape. It should be understood,however, that other shapes may be used, such as the shapes depicted inFIGS. 4A-4B, 5A-5B, and 6A-6B, or any other shape.

In the first exemplary ornamental design, as depicted in FIGS. 3A-3B,transaction card 140 may include a partially-curved shape in which oneend of transaction card 140 is generally rectangular and a second end oftransaction card 140 is generally rounded. In other exemplary ornamentaldesigns, the ends of transaction card 140 may include shapes that may becharacterized as triangular, angled, rounded, curved, scalloped, etc.FIGS. 4A-4B depict an exemplary design that includes an angled end.FIGS. 5A-5B depict an exemplary design that includes a triangular end.FIGS. 6A-6B depict an exemplary design that includes two rounded ends.Any combination of these are other shapes are possible. A transactioncard 140 with the design depicted in FIGS. 2, 3A, 3B is furtherdescribed below for ease of discussion only, and is not limiting.

As shown in FIGS. 3A-3B, exterior surfaces 212, 222 may form a majorityof the exposed surface area of transaction card 140. One or more ofexterior surfaces 212, 222 may include additional features, such asidentifying information (e.g., card number, customer name, customersignature, expiration date, security code, bar code, QR code, magneticstrip, etc.), additional transaction components 144, visual features(e.g., colors, designs, pictures, logos, bar codes, QR codes, etc.), andthe like.

FIG. 7 illustrates a cross-sectional view of assembled transaction card140, taken along line 5-5 of FIG. 3A. As shown, upper card component 204may be positioned in space 216 of lower card component 202. An adhesivelayer 702 may be placed between first interior surface 214 and secondinterior surface 224 to adhere bottom wall 206 to top wall 218. In thisway, upper card component 204 may be secured to lower card component202. Adhesive layer 702 may include any suitable adhesive material, suchas a hot melt adhesive, pressure-sensitive adhesive, etc. It should beunderstood, however, that other means of attaching upper card component204 to lower card component 202 may be used. For example, in someembodiments, upper card component 204 may be insert molded into lowercard component 202. Specifically, upper card component may be placedinto an injection mold and lower card component 202 may be injectionmolded around upper card component 204.

In some embodiments, an transaction component 144 may be positionedbetween first interior surface 224 and second interior surface 214. Forexample, an transaction component 144 may be embedded in adhesive layer702. In other embodiments, one or more transaction components 144 may bepositioned between adhesive layer 702 and either first interior surface214 or second interior surface 224 (e.g., with a second adhesive layerinterposed between the contacted surfaces (not pictured)). In stillother embodiments, one or more transaction components 144 may beembedded within upper card component 204 and/or lower card component202. In an embodiment, an EMV chip 230 (not pictured in FIG. 7) may besecured to first interior surface 214 via adhesive layer 702.

As shown in FIG. 7, a thickness of projecting wall 208 may define athickness 704 of transaction card 140. In an embodiment, thickness 704may be less than approximately 2 mm, which may be a thickness range fora transaction card 140 configured for contactless payments, for example.In another embodiment, the thickness of transaction card 140 may be lessthan approximately 1 mm. For example, projecting wall 208 may define athickness of approximately 0.76 mm. It should be understood, however,that transaction card 140 may include any thickness that corresponds toa device that could be considered a transaction card 140. In someembodiments, projecting wall 208 may define a rounded edge. Bottom wall206 may include a thickness 706 that is approximately one half of thethickness of projecting wall 208. For example, bottom wall 206 mayinclude thickness 706 in a range of approximately 0.3-0.4 mm.

With upper card component 204 positioned in space 216 of lower cardcomponent 202, a gap 708 may be formed around a perimeter thereof,between a side surface 709 of upper card component 204 and an inner sideof projecting wall 208, side surface 709 being generally perpendicularto second exterior surface 222. Gap 708 may provide a space forexpansion and/or contraction of upper card component 204 and/or lowercard component 202, and/or may allow for ease of removal upper cardcomponent 204 from lower card component 202 in applicable embodiments.In an embodiment, gap 708 may be approximately 0.15 mm. In addition, theinner side of projecting wall 208 may slope at an angle θ away from theside wall of upper card component 204. The slope of projecting wall 208may help guide insertion of upper card component 204. In one exampleembodiment, the angle θ may be approximately 10 degrees. Gap 708 mayadditionally or alternatively be an aesthetic element of the ornamentaldesign of transaction card 140.

Upper card component 204 may be positioned in space 216 such that secondexterior surface 222 is at the same level as or below the top ofprojecting wall 208. For example, upper card component 204 may bethinner than a depth of space 216 such that upper card component 204sits below flush by a space 710. In an embodiment, upper card component204 (e.g., top wall 218) may include a thickness of approximately 0.30mm, such that the space 710 is approximately 0.05 mm. In otherembodiments, top wall 218 may be flush with a top of projecting wall 208or top wall 218 (or a portion thereof) may extend above a top ofprojecting wall 208. Thus, a combined thickness of at least top wall 218and bottom wall 206 may define thickness 704. In embodiments thatinclude adhesive layer 702, thickness 704 may also include a thicknessof adhesive layer 702. In an example embodiment, the total thickness oftop wall 218 and adhesive layer 702 may be approximately 0.30 mm.

FIGS. 8A, 8B, and 9 illustrate another embodiment of transaction card140. In particular, FIGS. 8A, 8B, and 9 illustrate an example of atransaction card 140 after it has been assembled. FIG. 8A illustrates atop-view of transaction card 140. FIG. 8B illustrates a bottom-view oftransaction card 140. As shown in FIGS. 8A and 8B, transaction card 140may include a generally planar first exterior surface 212 and agenerally planar second exterior surface 222. Exterior surfaces 212, 222may be similar in size to that of conventional transaction cards. Lowercard component 202 and upper card component 204 may be configured suchthat exterior surfaces 212, 222, have any shape, as described, forexample, in relation to FIGS. 3A-3B, 4A-4B, 5A-5B, and 6A-6B.

Exterior surfaces 212, 222 may form a majority of the exposed surfacearea of transaction card 140. One or more of exterior surfaces 212, 222may include additional features (not shown), such as identifyinginformation, additional components 144, visual features, and the like.

FIG. 9 illustrates a cross-sectional view of transaction card 140, takenalong line 6-6 of FIG. 8A. As shown in FIG. 9, alignment feature 232 maypass through alignment feature 234 in order to position firsttransaction component 228 within 216. As also shown in FIG. 9, lowercard component 202 and upper card component 204 may align with eachother to form one continuous edge 902 that extends around a perimeter ofand between exterior surfaces 212, 222. The continuous edge 902 may beat least partially defined by projecting wall 208. Continuous edge 902may also be defined by one or more of bottom wall 206 and top wall 218.The continuous edge 902 may define a thickness 904 of transaction card140, which may be similar in size to conventional transaction cards. Forexample, the thickness 904 of transaction card 140 may be less than 0.1inches or less than 2 mm. These thicknesses are examples and transactioncard 140 may be defined by other thicknesses.

In an embodiment, the components of transaction card 140 may be formedsuch that lower card component 202 may define approximately two-thirdsof the thickness of transaction card 140, while upper card component 204may define approximately one-third of the thickness of transaction card140.

As shown in FIG. 9, lower card component 202 and upper card component204, when combined, form a cavity at space 216 for receiving transactioncomponents 144. The cavity may be formed by card frame 142 alone, andnot necessarily dependent on transaction components 144 that may bepositioned therein. In this way, card frame 142 may act as a shell forthe insertion of any transaction components that may fit therein. Thisavoids the problem of previous transaction cards, where the transactioncards are manufactured for use in combination with specific transactioncomponents. This feature allows transaction card 140 to be easilycustomizable, modular, and updatable. For example, new or differenttransaction component technology can be incorporated into a transactioncard 140 without changing the construction of card frame 142.

Card frame 142 may be constructed out of various materials that provideadditional advantages and customizability to transaction card 140. Forexample, card frame 142 may be constructed of soft touch plastics,hammered-texture materials, bead-blasted metals (e.g., aluminum), woodenmaterials (e.g., cherry, pine, ebony, oak, bamboo, etc.), sapphirecrystal materials (both pure and doped with titanium), natural fibercomposite materials, leather, ceramic materials, slate, etc. In someembodiments, card frame 142 may include additional material features,such as coverings (e.g., a silicone overmold), veneers (e.g., a woodenveneer), finishes (e.g. an oil-slick aluminum finish), or the like.

A number of factors may contribute to material choice based on anynumber of requirements for a transaction card. One of ordinary skillwill understand that different materials have advantages that are usefulin certain embodiments and use cases. For example, some materials may beused in part for low cost relative to other materials (e.g., soft touchplastic, aluminum, veneers, etc.). Other materials may be used in partfor durability (e.g., natural fiber composite materials, sapphirecrystal materials, metals, ceramic materials. etc.). Any number ofspecific aspects of durability may apply, for example resistance to oneor more of cracking, shattering, material erosion, color fading,warping, shrinking, etc. Still other materials may be used based on areputation for use in premium products as well as durability, weight, orvisibility (e.g., sapphire crystal materials, hammered texturematerials, natural fiber composite materials, leather, ceramicmaterials, slate, wooden materials, etc.). Material choice may also bebased on other properties such as conductivity, compatibility withtransaction card readers, water resistance, etc. The above examples arenot intended to limit the numerous properties that may be associatedwith any particular material.

In some embodiments, lower card component 202 and upper card component204 may be constructed out of different materials. For example, lowercard component 202 may be constructed out of a plastic material. Uppercard component 204, however, may be constructed out of a differentmaterial, such as a custom-selected material. The custom-selectedmaterial may include, for example, bamboo, ebony, copper, hammeredmetal, marble, or other materials that provide upper card with selectedornamental and/or performance characteristics, such as durability,strength, weight, rigidity, aesthetic design, color, contrast,uniqueness, etc., along with a distinctive look or feel. In this way,customers may customize the material of their respective transactioncard 140 In other embodiments, lower card component 202 may beconstructed out of a custom-selected material, such as those listedabove or any other material selected for its ornamental and/orperformance characteristics.

Lower card component 202 and upper card component 204 may bemanufactured using a suitable process. In an embodiment, upper cardcomponent 204 may be manufactured using a process dependent on the typeof material being used. For example, processes such as milling,grinding, sanding, hammering, injection molding, compression molding,and the like, may be used to construct upper card component 204. Lowercard component 202 may also be manufactured using a process selectedbased on the material being used. In an embodiment, lower card component202 may be constructed out of a plastic material using an injectionmolding process. Other processes that may be used to manufacture lowercard component 202 include compression molding, milling, etc.

FIGS. 10A and 10B further illustrate transaction card 140 during a stepof the manufacturing process. For example, lower card component 202 maybe manufactured to include one or more tear away portions 1002. As shownin FIG. 10A, the tear away portions 1002 may be temporarily connected toa rounded end portion of lower card component 202. The tear awayportions 1002, while attached to transaction card 140, may completegenerally rectangular shape for transaction card 140. In this way,transaction card 140 may be at least temporarily in the shape of aconventional transaction card (e.g., a typical credit card). This shapemay allow transaction card 140 to be used in existing machines that aredesigned to handle conventional rectangular cards. For example, thisshape may allow transaction card 140 to be sent through a machine thatadds printing, a magnetic stripe, visual design, etc.

After the transaction card 140 has completed any processes involving amachine that requires a rectangular shape, the tear away portions 1002may be removed, as shown in FIG. 10B. This feature allows transactioncard 140 to be used within conventional transaction card machinery,while also having any finished shape. It should be understood that thesingle rounded end shape depicted and described herein is one exemplaryornamental design and that transaction card 140 may have any finishedshape. Tear away portions 1002 may be shaped to fill in the gaps of thefinish shape of transaction card 140 to form a generally rectangularshape.

While illustrative embodiments have been described herein, the scopeincludes any and all embodiments having equivalent elements,modifications, omissions, combinations (e.g., of aspects across variousembodiments), adaptations or alterations based on the presentdisclosure. For example, in some embodiments, a single piece transactioncard may be used (e.g., a transaction card 140 with no inlay orbucket/lid), where the single piece transaction card may include one ormore of the features described herein (e.g., customized material,rounded edges, tear away portions, etc.).

The present teachings may also extend to one or more of the followingnumbered clauses:

-   1. A transaction card, comprising:    -   a card frame, including:        -   a generally planar first card component including a first            surface;        -   a generally planar second card component including a second            surface and defining a cavity,    -   wherein the first card component is separate from the second        card component and insertable into the cavity,    -   wherein, when the first card component is in the cavity, the        first surface forms a first exterior surface and the second        surface forms a second exterior surface, and    -   wherein the transaction card is defined by a thickness of less        than approximately 2 mm.-   2. The transaction card of clause 1, wherein:    -   the first card component is an inlay component including a first        wall having the first surface and a third surface, and    -   the second card component is a container component including:    -   a second wall having the second surface and a fourth surface;        and    -   a projecting wall extending from the second wall and defining        the cavity.-   3. The transaction card of clause 2, wherein the third surface is    attached to the fourth surface.-   4. The transaction card of clause 3, wherein the third surface is    attached to the fourth surface by an adhesive layer.-   5. The transaction card of clause 2, further including an electronic    component disposed between the third surface and the fourth surface.-   6. The transaction card of clause 5, wherein the electronic    component is embedded in an adhesive layer attaching the third    surface to the fourth surface.-   7. The transaction card of clause 5, wherein the electronic    component comprises at least an NFC antenna.-   8. The transaction card of clause 1, wherein the first card    component includes an opening for receiving at least a portion of an    electronic component.-   9. The transaction card of clause 1, wherein the first card    component is removable from attachment with the second card    component.-   10. The transaction card of clause 1, wherein the transaction card    is configured for use in conducting a financial transaction.-   11. The transaction card of clause 1, wherein the first card    component is manufactured from a first material and the second card    component is manufactured from a second material, and wherein the    first material is different than the second material.-   12. The transaction card of clause 11, wherein the second material    is a PC plastic material.-   13. The transaction card of clause 12, wherein the first material is    one or more of a soft touch plastic, hammered-texture material,    bead-blasted metal, wooden material, sapphire crystal material,    natural fiber composite material, leather, ceramic material, or    slate.-   14. The transaction card of clause 12, wherein the first material is    of bamboo, ebony, copper, hammered metal, or marble.-   15. The transaction card of clause 2, wherein the first card    component is inserted into the cavity such that the first surface    sits below a level of a top of the projecting wall.-   16. The transaction card of clause 2, wherein the inner side of the    projecting wall slopes away from the side wall of the first card    component at an angle of approximately 10 degrees.-   17. A method of manufacturing a transaction card, comprising:    -   forming a generally planar first card component from a first        material;    -   forming a generally planar second card component from a second        material, the second card component including a cavity;    -   inserting the first card component into the cavity and attaching        the first card component to the second card component,    -   wherein the first material is different than the second        material, and    -   wherein the transaction card is defined by a thickness of less        than approximately 2 mm.-   18. The method of clause 17, wherein forming the generally planar    second card component includes an injection molding process.-   19. The method of clause 17, wherein forming the generally planar    second card component includes forming at least one tear away    portion, the tear away portion completing a generally rectangular    shape for the transaction card and being removable from the second    card component such that the transaction card includes a finished    shape that is not rectangular.-   20. A transaction card, comprising:    -   a card frame, including:        -   a generally planar first card component defining a space;            and        -   a generally planar second card component, separate from the            first card component and attachable thereto to at least            partially enclose the space,    -   wherein the card frame is configured to hold at least one        electronic component in the space, and    -   wherein the transaction card is defined by a thickness that is        less than 0.10 inches.-   21. The transaction card of clause 20, wherein the first card    component comprises:    -   a first wall defining a first side of the transaction card; and    -   a projecting wall extending away from the first wall, and    -   wherein the first wall and the projecting wall at least        partially define the space.-   22. The transaction card of clause 21, wherein the projecting wall    defines at least a portion of a thickness of the transaction card.-   23. The transaction card of clause 21, wherein the first card    component further comprises a lip defining a support surface.-   24. The transaction card of clause 23, wherein the second card    component comprises a second wall defining a second side of the    transaction card, the second wall contacting the support surface.-   25. The transaction card of clause 24, wherein the second card    component further comprises an alignment wall extending away from    the second wall at a distance spaced from an edge of the second    wall, and wherein the alignment wall guides attachment of the second    card component to the first card component.-   26. The transaction card of clause 20, wherein at least one of the    first card component and the second card component include an    alignment feature.-   27. The transaction card of clause 26, wherein the alignment feature    includes an opening for receiving at least a portion of an    electronic component.-   28. The transaction card of clause 20, wherein the first card    component is removable from attachment with the second card    component.-   29. The transaction card of clause 20, wherein the transaction card    is configured for use in conducting a financial transaction.-   30. A transaction card, comprising:    -   a card frame, including:        -   a generally planar first card component defining a space;            and        -   a generally planar second card component, separate from the            first card component and attachable thereto to at least            partially enclose the space; and    -   at least one electronic component at least partially positioned        within the space,    -   wherein the transaction card is configured for use in conducting        a financial transaction.-   31. The transaction card of clause 30, wherein the first card    component comprises:    -   a first wall defining a first side of the transaction card; and    -   a projecting wall extending away from the first wall, and    -   wherein the first wall and the projecting wall at least        partially define the space.-   32. The transaction card of clause 31, wherein the projecting wall    defines at least a portion of a thickness of the transaction card.-   33. The transaction card of clause 31, wherein the first card    component further comprises a lip defining a support surface.-   34. The transaction card of clause 33, wherein the second card    component comprises a second wall defining a second side of the    transaction card, the second wall contacting the support surface.-   35. The transaction card of clause 34, wherein the second card    component further comprises an alignment wall extending away from    the second wall at a distance spaced from an edge of the second    wall, and wherein the alignment wall guides attachment of the second    card component to the first card component.-   36. The transaction card of clause 30, wherein at least one of the    first card component and the second card component include an    alignment feature.-   37. The transaction card of clause 36, wherein the alignment feature    includes an opening for receiving at least a portion of the at least    one electronic component.-   38. The transaction card of clause 30, wherein the at least one    electronic component includes at least one of an NFC antenna or an    EMV chip.-   39. The transaction card of clause 30, wherein the transaction card    is defined by a thickness that is less than 0.10 inches.

The elements in the following claims are to be interpreted broadly basedon the language employed in the claims and not limited to examplesdescribed in the present specification or during the prosecution of theapplication, which examples are to be construed as non-exclusive. It isintended, therefore, that the specification and examples be consideredas example only, with a true scope and spirit being indicated by thefollowing claims and their full scope of equivalents.

What is claimed is:
 1. A transaction card having a card frame,comprising: a first card component comprising a first card surface andan alignment wall protruding from the first card component opposite thefirst card surface; a second card component comprising: a second cardsurface and a third card surface opposite the second card surface, acavity formed in the second card surface for receiving the alignmentwall, and a removable portion configured to be removed during amanufacturing process; and a transaction component disposed between thefirst card component and the second card component.
 2. The transactioncard of claim 1, wherein a shape of the transaction card is defined by ashape of at least one of the first card surface or the second cardsurface.
 3. The transaction card of claim 2, wherein the shape of thetransaction card comprises at least one of a triangular card, a cardwith rounded edges, or a card with scalloped edges.
 4. The transactioncard of claim 3, wherein the removable portion, in combination with theshape of the transaction card, completes a generally rectangular shape.5. The transaction card of claim 1, wherein the removable portion isconfigured such that the transaction card can be used in a machineconfigured to accept a generally rectangular shaped card.
 6. Thetransaction card of claim 1, wherein the second card component furthercomprises a projecting wall extending from the second card surface andat least partially defining the cavity.
 7. The transaction card of claim1, wherein the transaction card has a thickness of less than 2 mm. 8.The transaction card of claim 1, wherein the transaction componentcomprises a first alignment feature and the second card componentcomprises a second alignment feature, wherein the first and secondalignment features are configured to position the transaction componentwithin the cavity.
 9. The transaction card of claim 8, wherein thesecond alignment feature is insertable into the first alignment feature.10. The transaction card of claim 1, wherein the first card component ismanufactured from a first material and the second card component ismanufactured from a second material, the first material being differentthan the second material.
 11. The transaction card of claim 10, whereinthe first material and the second material are selected from a groupconsisting of plastic, metal, wood, sapphire crystal, natural fibercomposite, leather, ceramic, or slate.
 12. The transaction card of claim1, wherein the transaction component comprises at least one of an NFCantenna or an EMV chip.
 13. The transaction card of claim 1, wherein thefirst card component further comprises a window configured to allow atleast a portion of the transaction component to project through thewindow.
 14. A method of manufacturing a transaction card, comprising:forming a first card component from a first material, the first cardcomponent comprising a first card surface and an alignment wallprotruding from the first card component opposite the first cardsurface; forming a second card component from a second materialdifferent from the first material, the second card component comprisinga second card surface, wherein the second card surface comprises acavity; forming a removable portion removably attached to the first cardcomponent, the second card component, or both; disposing a transactioncomponent between the first card component and the second cardcomponent; inserting the alignment wall into the cavity; and removingthe removable portion.
 15. The method of claim 14, further comprisingusing the transaction card in a machine configured to accept a generallyrectangular shaped transaction card.
 16. The method of claim 15, whereina shape of the transaction card is defined by a shape of at least one ofthe first card surface or the second card surface.
 17. The method ofclaim 16, wherein the shape of the transaction card comprises at leastone of a triangular card, a card with rounded edges, or a card withscalloped edges.
 18. The method of claim 17, wherein the removableportion, in combination with the shape of the transaction card,completes a generally rectangular shape.
 19. The method of claim 14,further comprising: forming a first alignment feature in the transactioncomponent; and forming a second alignment feature in the second cardcomponent; wherein the first and second alignment features areconfigured to position the transaction component within the cavity.